Download H-500 Fuel Cell Stack - Horizon Fuel Cell/Brasil H2
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H-500 Fuel Cell Stack User Manual V2.0 Updated 25 Jan 2010 OVERVIEW OF THE STACK Thank you for choosing our fuel cell stack. The Horizon fuel cell stack is an air-cooled, light weight and compact fuel cell stack. Please read all instructions carefully prior to product use and keep this manual for future reference. Further copies can be obtained from Horizon Fuel Cell Technologies or by emailing: Please refer to the Horizon website for latest information: www.horizonfuelcell.com [email protected] Specifications and descriptions in this document were in effect at the time of publication. Horizon Fuel Cell Technologies reserves the right to change specifications, product appearance or to discontinue products at any time. IMPORTANT In order for the warranty to come into effect the stack must be registered on the Horizon Warranty Page at: www.horizonfuelcell.com/warranty.htm Do not attempt, under any circumstance, to disassemble or inappropriately tamper with the fuel cell. There will be no returns, refunds or exchanges should disassembly or tampering occur. If you have questions or need help with regards to the fuel cell and its technology contact: [email protected] H-500 Fuel Cell Stack User Manual V2.0 Table of Contents 1. Terminology............................................................ 1 2. Stack and System Component Information............. 5 3. Technical Specifications......................................... 7 4. System Set Up....................................................... 8 5. Notes fot the set up ................................................ 14 6. System Setup Diagram .......................................... 16 7. Polarization Curves................................................ 17 8. Operating Instructions............................................ 18 9. Trouble Shooting & Suggestions............................ 18 H-500 Fuel Cell Stack User Manual V2.0 1. Terminology PEM fuel cell: a PEM (Proton Exchange Membrane) fuel cell is a device that converts hydrogen and oxygen into water and electricity. Reactants: reactant is a material used to start a chemical reaction. In the fuel cell the reactants are air and hydrogen by which the electricity will be generated. Humidification: humidity that the fuel cells need for running. Blower: supply air to the fuel cells and meanwhile decrease the temperature in the stack. Mass flow per minute: the total amount of the hydrogen flow through the fuel cell every minute, which the hydrogen supply can be calculated. HFCT: Horizon Fuel Cell Technologies H-500 Fuel Cell Stack User Manual V2.0 1 A B E D C A: Hydrogen Inlet connector B: Blower C: Hydrogen Outlet connector D: Supply valve E: Purge valve H-500 Fuel Cell Stack User Manual V2.0 2 E C D B A A: Lable (FC- and Load-) B: FC- and Load- connecter C: FC+ connecter D: Lable (FC+) E: Warning Labels H-500 Fuel Cell Stack User Manual V2.0 3 A C B L E H J K D F G I A: Logo B: LED C: Product No.Label D: Connect plug E: SCU(short circuit units) switch F: ON/OFF button G: Connect to FC+ H: Connect to FCI: Connect to Load+ J:Controller power supply DC 13V+ K:Controller power supply DC 13VL:LCD connecter H-500 Fuel Cell Stack User Manual V2.0 4 2. Stack and System Component Information 1. Stack Is made up of plate-like cells with air channels to allow the flow of air across the membrane. The membrane facilitates the flow of Hydrogen creating the release of electrons. Electrically conductive separator plates between each pair of cells enable the flow of electrons. The stack aspect is that they are all placed on top of each other and held together by epoxy endplates. 2. H2 Supply Valve and purge It controls the H2 input. When the controller turns on, also the H2 supply valve does. When system turns off, it is in the off position for preventing the leakage. 3. Short Circuit Unit The short circuit unit can be turned on or off depending on what application the stack is to be used in. It ensures enhanced performance of the fuel cells in applications where the stack is turned off for prolonged periods. 4. On/Off Switch It is the switch of the controller. Hold it for 5 seconds for either on or off. 5. Blower Supply air to the fuel cells and meanwhile decrease the temperature in the stack. H-500 Fuel Cell Stack User Manual V2.0 5 6. Controller Connector Connect the stack cables to the lead wires of the T-sensor/ blower/purging valve/input valve on the controller. 7. Controller Controls the stack temperature, blowers, hydrogen input, purging and short circuiting of the stack. 8. H2 out & H2 In: connect tube in 10 below H2 OUT: connect tube shown in 10 below. H2 IN: connect tube shown in 10 below. 9. Fuel Cell +/- Load Connectors FC+ is connected to the fuel cell positive pole. FC- is connected to the fuel cell negative pole. 10 . Tube for H2 Input & Output The tube with 6mm outer diameter and 3mm inner diameter is connected to the H2 Inlet and outlet as in 9 above and to the input valve and output valve of the hydrogen source. 11 . Fittings For connecting the load. H-500 Fuel Cell Stack User Manual V2.0 6 3. Technical Specification Type of fuel cell PEM Number of cells 36 Rated power 500W Rated performance [email protected] Output voltage range 18V-34V Weight (with fan & casing) 4.2kg(9.3lbs) Size 130 x 220 x 122 mm Reactants Hydrogen and Air Rated H2 consumption 7L/min Hydrogen pressure 0.5-0.6Bar(7.2-9.4PSI) Controller weight 0.45kg (0.99lbs) Hydrogen supply valve voltage 12V Purging valve voltage 12V Blower voltage 6-12V Ambient temperature 5-30°C (41-86°F) Max stack temperature 65°C (149°F) Hydrogen purity 99.999% dry H2 Humidification Self-humidified Cooling Air (integrated cooling fan) Start up time Immediate Efficiency of system 40%@22V *the flow rate may change with the power output **system electronics need external power supply H-500 Fuel Cell Stack User Manual V2.0 7 4. System Set-Up STEP1: Connect the connectors of the controller and the stack to get the blower, the temperature sensor, the hydrogen supply valve and the purge valve under control. The finished connection is shown in 1B. 1A 1B H-500 Fuel Cell Stack User Manual V2.0 8 STEP2: Connect the controller and the stack as the output power also should be under control. The finished connection is shown in 2E. 2A 2B 2C 2D 2E H-500 Fuel Cell Stack User Manual V2.0 9 STEP3: Connect the stack to a stabilized voltage supply through the “13V DC” connectors (3A), and the voltage of the power should be between 12V and 14V. 3A STEP4: Keep the SCU (Short Circuit Unit) switch at 1 normally. Only if the short circuit effects the operation, you can use the switch to shut off the short circuit, but it will cause at least 20% performance loss. 4A STEP5: Connect the outside hydrogen supply valve to the stack. The hydrogen supply valve will prevent damage from the hydrogen while the stack is off. Notice the direction of the connection of the Hydrogen supply valve. The finished connection is shown in 5H. 5A H-500 Fuel Cell Stack User Manual V2.0 5B 10 5C 5D 5E 5G 5F 5H H-500 Fuel Cell Stack User Manual V2.0 11 STEP6: Connect the stack to the purge valve through the filter for a longer running time and a better performance (6A-6E). If not, the gas out of stack may have a negative effect on the purge valve after a long time running. Connect the output of the purge valve to a place away from the stack in case of the damage caused by the hydrogen leakage. 6A 6C 6B 6D 6E H-500 Fuel Cell Stack User Manual V2.0 12 STEP7: Check all the connection first and connect the load to the system, Load+ is linked to the "load+" at the controller, Load- links to the "FC- and load-" in the stack shown in 7A 7A STEP8: Provide hydrogen and stabilized voltage first and then press the ON/OFF switch to start the system. 8A H-500 Fuel Cell Stack User Manual V2.0 13 5. Notes for the set-up Stack should be placed like this position. The voltage of external power supply is between 12V - 14V, the current range is different based on the different stack. It should be as short as possible between stack and valve. It should be less than 0.3M between the pressure regulator and the stack. The pressure of the hydrogen is between 0.4--0.45Bar (0.04 -- 0.045Mpa). The load connecter, load+, is connected to the "load +"in the controller. Connected the load- to "FC- & Load-" in the stack. H-500 Fuel Cell Stack User Manual V2.0 14 The outlet of the purge valve should be far away from the stack. Don't let the hydrogen from purge valve back to the stack, otherwise it would damage the stack. H-500 Fuel Cell Stack User Manual V2.0 15 6. System setup diagram FC- & Load- H-500 Fuel Cell Stack User Manual V2.0 16 7. Polarization curves V H500 U-I Curve 40 35 30 25 20 15 10 5 A 0 0 5 10 15 20 25 30 H500 U-I Curve 8000 ml H500 H2 flow 7000 6000 5000 4000 3000 2000 1000 W 0 0 100 200 300 400 500 600 H500 H2 f low 600 W H500 P-I Curve 500 400 300 200 100 A 0 0 5 10 15 20 25 30 H500 P-I Curve H-500 Fuel Cell Stack User Manual V2.0 17 8. Operating instructions Step 1: Set up the fuel cell system according to the diagram above, make sure that: - The external DC power supply voltage is between 12V to 15V. - The pressure is between 0.05 to 0.065Mpa. (7.2-9.4psi) Step 2: Connect the load to the “FC- & load-” and “Load +”. Step 3: Start the power supply and Hydrogen supply. Step 4: Press ON button and the fuel cell system is ready to use. 9. Trouble Shooting & Suggestions If the stack is not used for a long time (months), it will take a little time to get the manual power, It need 5-30mins If the system shuts down by itself check the following details: 1. Make sure you have connected all wires according to the diagram. 2. Make sure the external voltage is 12V -15V. The curremt range is over 10A. 3. Make sure you have a hydrogen supply. 4. Make sure the load is below 1000W, because the controller will protect the stack from drawing too much current. 5. Check whether the fuel cell temperature is below 65oC, the system will shut off if it is above 65oC. Note: 1. Disconnect the hydrogen supply completely if the fuel cell stack is not in operation for more than 4 hours. 2. Use a tube to connect the fuel cell stack hydrogen inlet to the outlet if the fuel cell stack is not in operation. 3. Ensure that the 99.999% of the Hydrogen used is dry. Overuse of humidifiers may cause irreparably damage. 4. Ensure that white nozzle on the purging valve is connected to the fuel cell Hydrogen outlet. 5. The hydrogen outlet must be 20cm away from the fuel cell stack, because the MEA will be damaged permanently if there is hydrogen and oxygen available simultaneously Do not attempt, under any circumstance, to disassemble or inappropriately tamper with the fuel cell. There will be no returns, refunds or exchanges should disassembly or tampering occur. If you have questions or need help with regards to the fuel cell and its technology contact: [email protected] H-500 Fuel Cell Stack User Manual V2.0 18